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Confidential. Copyright © The University of Sheffield / AMRC May-18..Template: AMRC.PPT – Revision 4 (May 2018)
In-process Inspection for AFP of Composite Parts
Mr. Zeeshan Qureshi
(Research Engineer, CEng)
31.10.2018
Advanced Engineering Show 2018
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Contents
2
• Need for Automation
• Automated Fibre Placement (AFP) Defects
• Inspection Hardware
• Automated Inspection System
• Case Study: Inspection Trials at AMRC
• Engineering Challenges & Future Development
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Need for Automation
3
• Traditional hand lay-up process of composite materials is inappropriate for large parts.
• Increasing use of Automated Fibre Placement (AFP) in aerospace sector for large and complex parts to meet product demands.
Repeatable process
Faster and more accurate
[Modern Airliners, B787]
Gantry AFP System [Electroimpact]
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Need for Automation
4
• Challenge: Inspection of composite lay-ups is manual and very time consuming.
• Manual inspection takes a significant proportion of the total AFP time (2/3).
• Need for Automated Inspection System.
[Inspections of Large Complex Parts (GKN)]
[Inspection of Small Simple Parts at AMRC]
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AFP Defects
5
Gaps & Overlaps
Twists & Angle Deviation Splices FOD
Others: Bridging, Loose tow, Fold-overs, Buckled tow
Roped TowWrinkled tows
Tow Add & Cut Position Error
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Inspection Hardware
6
IR Cameras [FLIR] Light Scanners [Hexagon] Laser Line Scanners [Keyence]
Imaging Sensor [Teledyne]
Sub-Terahertz[TeraSense]
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Automated Inspection System
7
• Aim: Robustness, Speed and Accuracy.
• Inspection Methodologies: Global vs Local? On-the-fly vs Post layup?
Inspection Hardwares(Cameras, Laser line
scanners, etc.)
Robot Position(Linear & Angular)
Inspection Software(Data Synchronisation
& Processing)
CAD(Design Intent)
Manufacture Report
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Case Study – Inspection Trials at AMRC
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• Composite prepreg and dry fibre samples were produced with:
Gaps/overlaps
Tow start/cut errors
• White light scanner 400 mounted onto a 6-axis robot.
• Multiple images of the samples were captured:
At different locations and orientations.
To generate a global point cloud of data.
• Data post-processed in 2 softwaresto generate plots and measure defect sizes.
White Light Scanner 400
[Hexagon]
Fibre placed composite
sample
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Case Study – Inspection Trials at AMRC
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• Manual post-processing of data was time consuming.
• Height contour plots -> gaps overlap.
• Highlighting of tow edges -> start/cut errors & gaps/overlaps.
• Defect measurements performed manually.
• Recent projects have involved integration of automated inspection system with the AFP.
Post-processed Plots
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Engineering Challenges & Future Development
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1. Efficient handling of LARGE scan data.
2. Robust software algorithms.
3. Sensors with large working distance.
4. Robots with good positional accuracy.
5. Computational analysis to predict material behaviour.
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Acknowledgement
11
• AMRC Partner companies
• AMRC Composite Centre team
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Email:
Tel:
web: amrc.co.uk
Twitter: @theAMRC
Thank you.For further information please contact or visit:
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